Refratechnik Steel GmbH

Schiessstrasse 58
40549 Dsseldorf
Germany
Phone: +49 211 5858 0
Fax: +49 211 5858 49
steel@refra.com
www.refra.com

Processing instructions V 4.2

REFRAJETCAST Nanobond
Note: Please read the product information sheet first, to ensure that these are the right
processing instructions for your product. This document describes the application procedure for dense, cement-free REFRAJETCAST refractory concretes of the type Nanobond (three-component material).
The instructions contained in this document must be complied with during processing and
installation of the respective refractory concrete. Modification of or deviations from the
processing instructions can lead to major problems during installation, and possibly to
total failure of the installed refractory material. These instructions provide general guidelines for storage, processing, and installation of the specific refractory material. If, due to
specific site conditions, it appears necessary to deviate from the procedures described
here, please consult Refratechnik Steel GmbH before starting work.

Storage
In general: Store under cool, dry, and
frost-free conditions.
The liquid binding agent and the accelerator must always be stored at a temperature of > 5 C.
The shelf life stated in the product information sheet is valid from the production date, and only if storage is in accordance with our recommendations.
The production date is stated on the
packaging label.
Under certain circumstances, material
that has been properly stored may still
be usable even after expiry of the stated
shelf life. In such a case, conduct a setting test with a sample before using the
material. In case of doubt, the expired
material can be checked by Refratechnik
Steel GmbH.
Incorrect storage can greatly reduce
shelf life, and can impair product quality.
The original pallet wrapping foil should
be left intact for as long as possible to

protect the product. However, the foil is

not a substitute for storage under cover.
Also standing water, e.g. due to inadequate drainage of the storage area, can
damage the material.
Stacking of the goods supplied by us (in
sacks, Big Bags, etc.) is done under the
sole responsibility of the shipping company or customer. Refratechnik Steel
GmbH accepts no liability for possible
consequential damage (damaged packaging, personal injury, etc.).
Health and safety
Always wear suitable safety goggles,
dust mask, protective clothing, and
working gloves.
Always wash thoroughly after working
with the material.
Observe the safety data sheets of the
dry material, the accelerator, and the
liquid binding agent.

General information
This product is a cement-free, inorganically-chemically setting refractory concrete. Delivered dry in 25 kg sacks or in
Big Bags, it is mixed with the liquid
binder on site. Curing occurs at room
temperature during gunning, and exclusively through the addition of an accelerator. When used as a casting compound, curing occurs at room temperature after an accelerator in powder form
has been added to the dry component.
The following application methods are
possible:
1. By means of the JETCAST process
(shotcreting)
2. By casting the compound (only after
consultation with Refratechnik Steel
GmbH)
REFRAJETCAST Nanobond products
are three-component materials:
- Component 1: Dry material, delivered
in 25 kg sacks or in Big Bags
- Component 2: Liquid binding agent,
delivered in 1000 kg PE canisters or 3 l
IBCs
- Component 3: Accelerator, delivered in
30 or 100 kg PE canisters or drums

Processing instructions V 4.2

REFRAJETCAST Nanobond

Always mix complete packaging units (1

sack or 1 Big Bag). The use of partial
quantities can lead to demixing and
changed material properties.
The dry mixture is then mixed exclusively with the liquid binding agent supplied
never add water.
The liquid binding agent and the accelerator must always be stored at a temperature of > 5 C. During processing,
the temperature of the mixed concrete
must also be kept at > 5 C.
Low temperatures can retard or even
stop the setting process. Therefore, the
temperature of material and liquid binding agent must be at least 5 C. In some
cases, it might be necessary to heat the
installation area.
On the other hand, the setting process
may be significantly accelerated at temperatures above 25 C.
Please take the expansion of the refractory material for your specific furnace
application into account. The reversible
and irreversible expansion values and
the respective material properties are
given in the product information sheet.
Depending on the furnace operating
conditions and the specific characteristics of the refractory material, any arising stresses and pressures must be
compensated by suitably designed expansion joints.
During installation of the monolithic refractory material, please ensure correct
anchoring to the existing furnace structure and/or to the existing or adjacent
refractory material (e.g. with steel anchors, ceramic anchoring systems, etc.).
Suitable measures must be taken to ensure that the water or water vapour
generated during the drying & heating
up process is removed from the refractory lining without pressure build-up.
With certain furnace structures and refractory linings, the drying process can

cause water or water vapour to diffuse

outwards in the direction of the furnace
shell instead of inwards to the hot side
(furnace chamber). Therefore, suitable
measures must be taken to ensure that
the water or water vapour can escape to
atmosphere. For this purpose, 10-mm
holes drilled into the outer furnace surface (at least 5 per m) have proved to
be successful.
In order to ensure a continuous drying
process, the entire furnace chamber
must always be flushed with an adequate amount of fresh air during the entire drying and heating up procedure.
The air circulating in the furnace chamber may never be saturated with moisture.
Mixing
REFRAJETCAST products are always
delivered together with a liquid accelerator for the JETCAST gunning process
(shotcreting). On no account may the
accelerator be mixed with the concrete.
The accelerator and the liquid binding
agent must always be stored frost-free.
Mixer, tools, conveying equipment, etc.
must be clean and free from any form of
contamination.
Use of a positive mixer is essential.
Mix only as much material at a time, as
can be processed within about 50
minutes.
Data on the maximum and minimum
amounts of liquid binding agent to be
added is given in the product information sheet or on the packaging label.
Please note that the quantities to be
added are stated in l/100 kg or kg/100
kg.
If in doubt about the reactivity of the
liquid binding agent (e.g. if its shelf life
has expired or undefined storage conditions, etc.), please contact the R&D
Dept. of Refratechnik Steel GmbH before
starting work.

First, briefly mix the dry material for

about 30 seconds to restore the consistency after any demixing that might
have occurred during transport.
Next, add the minimum amount of liquid
binding agent while continuing to mix
the material. Continue mixing for about
2 minutes until a thorough mix is obtained.
Frequently, the required consistency is
obtained only at the end of the mixing
period, because the fine portions in the
product must be broken down first.
Therefore, you should wait until the full
mixing time has elapsed, and don't try to
obtain the required consistency in a
shorter time by adding more liquid binder. The material's consistency can
change quite abruptly from "too dry" to
"exactly right". If necessary, the remaining amount of liquid binding agent can
be added until the required consistency
is obtained. Hereby, the maximum
amount of liquid binding agent may not
be exceeded.
Then continue mixing for about 2 more
minutes.
Do not exceed the maximum permitted
mixing time of 5 minutes.
No foreign bodies or particles of concrete that have already set must be allowed to enter the freshly mixed concrete, as these can cause premature setting.
Processing
1. Application with the JETCAST process (shotcreting)
Basics of the JETCAST process: After
mixing, the concrete is filled into the
hopper of a dual-piston concrete pump,
from where it is conveyed to the jet mixing chamber through pipes and hoses in
a continuous stream of material. In the
mixing chamber, a blast of compressed
air and liquid accelerator breaks up and
plasticates the material stream to such
an extent that the concrete can be

Processing instructions V 4.2

REFRAJETCAST Nanobond

gunned horizontally and also vertically.

By means of a control valve on the nozzle, the operator manually adjusts the
precise amounts of compressed air and
accelerator. Start with the lowest accelerator dosage, and then increase it until
the material plasticizes on the installation surface. Avoid an excessive amount
of accelerator liquid. The correct amount
is between 0,2 and max. 0,7 percent by
weight.
In the past, the equipment from Montanbro, Allentown, and Pumpmore has
proved to be suitable for processing
REFRAJETCAST products.
The accelerator pump must be capable
of delivering a pressure of at least 20
bar.
The compressor used for injecting the
accelerator/air mixture must have a minimum capacity of 7,5 m3/min and 7,5
bar.
The transport distance should always be
kept as short as possible. Therefore, the
machine should be located as close as
possible to the installation site.
Rigid pipes are preferable to rubber hoses for conveying the mixture, because
their internal friction losses are less.
Before starting work, pipes and hoses
must be flushed out with a suitable lubricant.
A continuous flow of material is a prerequisite for a homogeneous material
structure. Therefore, an adequate
amount of material in the hopper of the
dual-piston pump must always be ensured.
No moisture may be drawn out of the
gunned material by adjacent dry and absorbent surfaces. Therefore, any existing
refractory lining should be pre-wetted
before gunning. Any moisture-sensitive
materials, such as insulation, should be
covered with foil.

The distance between gunning nozzle

and application surface must not be
more than 30 cm.
On no account may rebound material be
reused.
Individual bays (bay size about 1 m2)
should be gunned successively, taking
care not to gun areas that have already
stiffened or cured (risk of layer formation
and spalling).
The surface can be touched up immediately after gunning.
2. Application as casting compound
REFRAJETCAST concretes are intended primarily for gunning (shotcreting)
applications. Within certain limitations,
the material can also be processed like
normal grouting concrete. Please consult Refratechnik Steel GmbH before
processing the material as a casting
compound.
REFRAJETCAST products are always
delivered together with an accelerator
for the JETCAST process. Do not use
the accelerator if the material is to be
processed as a casting compound.
Before processing the casting compound, an additive in powder form must
be added to the dry material. This additive can be purchased from Refratechnik
Steel GmbH on request.
If using formwork, make sure it is sufficiently stable, and that its surfaces are
smooth. Use formwork release oil.
No moisture may be drawn out of the
cast material by adjacent dry and absorbent surfaces. Therefore, any existing
refractory lining should be pre-wetted
before casting. Any moisture-sensitive
materials, such as insulation, should be
covered with foil.
While casting the material, or shortly
afterwards, the concrete must be com-

pacted by vibration (e.g. with an internal

vibrator).
If an internal vibrator is used, continue
the vibration only until no further compaction is evident. To prevent air inclusions, withdraw the vibrator slowly from
the concrete.
Setting and curing
As opposed to cement-bonded refractory
concretes, Nanobond bonded concretes
generate a negligible amount of heat
during curing. Cooling of the concrete
surface by spraying it with water, as
generally done with cement-bonded
concretes, is not required for Nanobond
concrete.
The following applies for processing as a
casting compound: Generally, it takes
between 6 and 12 hours before the concrete has cured sufficiently to permit
removal of the formwork. Ambient temperatures in midsummer may considerably shorten this time, while winter temperatures or the use of material stored in
cold places may lengthen it. Of course,
the formwork may only be removed after
the material has fully cured. The right
time to do this can be determined reliably by means of a ring test: Lightly
strike the accessible face of the lining
with a small hammer. As curing proceeds, the tone changes from dull to
bright. A bright tone, which no longer
changes, is generally an indication that
the formwork may be removed.
Caution: In some cases, the lining might
not yet be solidified. Therefore, if in
doubt, wait with removal of the formwork.
Full setting of the refractory concrete
requires at least 24 hours. Until that
time, the concrete must be protected
from frost.
In a direct comparison, the strength of
Nanobond concrete after setting (24
hours) is lower than that of hydraulically
bonded concretes. However, its strength
increases significantly after drying, and

Processing instructions V 4.2

REFRAJETCAST Nanobond

above a temperature of about 800 C it

is equal to that of liquefied, hydraulically
bonded refractory concrete.
Drying and heating up
Compared with hydraulically bonded
refractory concretes, Nanobond bonded
concretes are significantly less sensitive
during heat-up. Drying and heating up
can be started immediately after removal of the formwork (for cast material) or
after completion of the JETCAST application.
During the first heat-up, also make sure
that no other materials are heated up,
which are not suited for fast heating up.
Please check the product information
sheet to ensure that you have the right
heat-up instructions for your product.
The heat-up instructions must always be
followed precisely.

Author: LSM / Date: 4/2015